This study explored the feasibility of fluoride removal from simulated semiconductor industry wastewater and its recovery as calcium fluoride using fluidized bed crystallization. The continuous reactor showed best performance (>90% fluoride removal and >95% crystallization efficiency) at a calcium to fluoride ratio of 0.6 within first 40 days of continuous operation. The resulting particle size increased by more than double during this time along with a 36% increase in the seed bed height indicating deposition of CaF2 onto the silica seed. The SEM-EDX analysis showed the size and shape of the crystals formed along with high amount of Ca-F ions presence. The purity of the CaF2 crystals were determined to be 91.1% though ICP-OES analysis. Following the continuous experiment, different process improvement strategies are explored. The addition of excess amount of calcium resulted in an additional 6% fluoride removal, however, compared to this single stage process, a two-stage approach was found to be better strategy to achieve a low effluent fluoride concentration. The fluoride removal reached 94% with this two-stage approach under optimum condition of 4 + 1 h HRT combinations and a [Ca2+]/[F-] ratio of 0.55 and 0.7 for the two reactors, respectively. CFD simulation showed the impact of inlet diameter, bottom-angle shape and width and height ratio of the reactor on mixing inside reactor and possibility of further improvement in reactor performance by optimizing the FBR configuration.